Door structure put together, and its skinned. The filler panel forward of the hinge is clecoed into place.

Everything seems to fit and line up. Next is some minor detail work on the door, and the inner seal frame on the vehicle side. Eventually I'll get the windows for the bus - I am planning on two windows, a curb view low one and a high one. I thought about figuring out how to make the bottom window a doggie door.

Man...you cannot imagine how much I envy anyone with a flat door. Putting mine together was a shipbuilders nightmare. Finally got it to fit, then the whole thing racked out of shape just enough that I now need to force it (somehow) back into shape.

I'm glad someone mentioned visibility from that angle - I think I kept sliding that upper hinge around for like an hour trying to balance optimal physics with practicality. The compromise is at my tallest in the air ride seat, I can just see a bit of the horizon once I stick a window in the door.

I'll get a lower window too - and I was planning on a tiny kidney bean window in that space between what I guess would be called the a pillar and the forward door seal.

Thanks for comments it helps keep things moving.

Quote:

Originally Posted by cowlitzcoach

That door looks great!

My only comment is I hope you are not a very tall person. If you are I think you will find your top hinge is going to be blocking your view out to that side of the bus.

The early Prevost H3 buses had a cross bar at about the same height. It didn't bother short drivers but it was right in the middle of the way for me.

Your attention to detail and the quality of your work is commendable. I doubt you would be able to pay for that kind of quality in any shop regardless of price.

I unhung and rehung that door about eleventy hundred times to make sure I didn't accidently bend it out of shape when mocking it up. A while ago after I read your build posts I decided a flat door was for me and took note of the trouble you had, so what you had to go through wasn't entirely a loss. (Thanks!)

If your door is parallelized just slightly wrong and you have the skin on it, you'll need to release the tension in the sheet metal first. Easier to figure it out If I could poke at it though.

Quote:

Originally Posted by Tango

Man...you cannot imagine how much I envy anyone with a flat door. Putting mine together was a shipbuilders nightmare. Finally got it to fit, then the whole thing racked out of shape just enough that I now need to force it (somehow) back into shape.

OK, so door is done enough for now. The interior framework has needed attention. Once it is painted and bolted into place again, I can start adding walls, lights, chases for plumbing and wiring etc.

So start by unbolting everything, then a little wire wheel, flap disc, and 3m scotchbrite pad action, then a little cleaning with a fresh painter rag and lacquer thinner.

I would love to powdercoat all the pieces but pretty much everything is cost prohibitive for me.

I've found that if you have a decently prepped surface this combination of paint works well for bare metal, the rustoleum acid etch primer and their "professional" spray paint. They are both high build products that dry fast.

Perfect for penny pinching impatient people like me.

The weather is crappy but we had a sunny break today and took advantage of it as much as possible. I got a large chunk of the framework painted but it seems never ending.

I still have a few large pieces bolted in that have to come out, and I haven't even gotten to the kitchen cabinet system yet.

Before I bolt everything back in, I'll be installing the finished interior wall covering in many places which should give the appearance of some actual progress.

Once all the framing I have now is bolted into place I'll get to work on the drawers and stuff for the kitchen. The pantry is a full height (78 inch) pull out system, and a bunch of drawers and stuff that I fabricated earlier. I'm looking forward to that part.

I'm guessing I'm still missing a few framework pieces, notably the crossover partitions from left to right, sliding door for the master bed in back, the shower stall framing, and the slider for the bathroom.

The shower will be interesting, I plan on using a 30x30 4 piece shower kit.